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Model M3345

Line Regeneration Module for AC Drives

Customer Reference Manual

Summary of Contents for M3345

Page 1: ...Web www bonitron com Tel 615 244 2825 Email info bonitron com Model M3345 Line Regeneration Module for AC Drives Customer Reference Manual ...

Page 2: ... and engineering labs for prototype testing and evaluation Production facilities include production areas for circuit board assembly a machine tool and sheet metal shop for chassis fabrication and a systems assembly and checkout area With these assets Bonitron is positioned to be a leader into the future while maintaining first class support for their current customer base Worldwide sales of equip...

Page 3: ...ir plant process computers Since that time Bonitron has developed AC drive option modules that help overcome many of the problems encountered in applications of modern AC variable frequency drives Bonitron s Ride Thru module provides protection from AC line voltage sags while the Line Regen and Resistive Braking modules provide DC Bus regulation for over voltage due to regenerated voltage Bonitron...

Page 4: ...assis 10 Table 3 3 Power Terminal Specifications 120 Amp Chassis 10 3 4 2 I O Wiring 10 Table 3 4 I O Terminal Specifications S Chassis 10 Table 3 5 I O Terminal Specifications B and X Chassis 11 Table 3 6 I O Terminal Specifications Y C W Z and V Chassis 11 Figure 3 2 S Chassis Connections 11 Figure 3 3 W Chassis Connections 11 Figure 3 4 V Chassis Connections 12 Figure 3 5 X and B Chassis Connec...

Page 5: ...Table 6 3 Ratings and Specifications 460VAC 27 6 2 Watt Loss 28 6 3 Certifications 28 6 4 Fuse Circuit Breaker Sizing and Rating 28 Table 6 4 Replacement Fuses 28 6 5 Dimensions and Mechanical Drawings 29 Figure 6 1 M3345 S Chassis Dimensional Outline 29 Figure 6 2 M3345 W Chassis Dimensional Outline 30 Figure 6 3 M3345 V Chassis Dimensional Outline 31 Figure 6 4 M3345 B Chassis Dimensional Outlin...

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Page 7: ...his manual is a user s guide for the Model M3345 Line Regen Control modules It provides you with the necessary information to successfully install and use the M3345 modules in your application In the event of any conflict between this document and any publication and or documentation related to the application the latter shall have precedence 1 3 MANUAL VERSION AND CHANGE RECORD Ratings Charts are...

Page 8: ...ive to the AC line This provides for regulation of the DC bus and prevents the drives from tripping on overvoltage When a dynamic braking resistor is used with a PWM drive the regenerated energy is dissipated as heat and energy is wasted When the Model 3345 Regen Module is used the regenerated energy is returned to the input AC line with near unity power factor Substantial energy savings may occur...

Page 9: ...Amps 6 120 Amps CHASSIS STYLE Table 2 3 Chassis Styles CHASSIS CODE DESCRIPTION SIZE H X W X D S 10 45 Amps Type 1 enclosure 17 75 x 6 00 x 11 00 B 10 45 Amps Type 13 JIC type wall mount enclosure without fan 17 50 x 16 25 x 8 25 with fan 17 50 x 18 50 x 8 25 X 10 45 Amps Open chassis panel mount backplate without fan 15 00 x 15 10 x 8 50 with fan 15 00 x 18 00 x 8 50 Y 30 90 Amps Open chassis pan...

Page 10: ...s required for your application SPECIAL OPTIONS A 0 in this position indicates the unit is not Master Slave selectable An M in this position indicates the unit is 60A or higher and is Master Slave selectable ATTENTION Units with current ratings of 60 90 Amps will support Master Slave operation Units with current ratings of 10 45 Amps and of 120 Amps will not support Master Slave operation FREQUENC...

Page 11: ...C E W I T H C L E A R A N C E S O F A T L E A S T T W O I N C H E S I N A L L D I R E C T I O N S AL W A Y S A L L O W A M P L E T I M E F O R T H E U N I T T O C O O L B E F O R E A T T E M P T I N G S E R V I C E O N T H I S P R O D U C T BE F O R E A T T E M P T I N G I N S T A L L A T I O N O R R E M O V A L O F T H I S P R O D U C T B E S U R E T O R E V I E W A L L D R I V E A N D O R R E S ...

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Page 13: ...n any way please contact the supplier from which the product was purchased 3 3 MOUNTING The installation site for the module should be chosen with several considerations in mind When mounting Regen units in an enclosure power dissipation should be taken into account Refer to Section 6 2 Watt Loss for details The unit requires a minimum clearance of two 2 inches in all directions around it when mou...

Page 14: ...M3345 8 Figure 3 1 M3345 Mounting Orientation C A VERTICAL SURFACE HORIZONTAL TO FLOOR UP UP HANGING UNDERSIDE UP HORIZONTAL SURFACE B Dwg 070131 Rev 20070524 ...

Page 15: ...e connected to the utility grid side If an isolation transformer is to be used the regen AC input MUST be connected to the same point as the drive AC input Do not connect to a generator unless minimum load at any time exceeds the peak expected regen power The regen units are not phase sensitive Insure that the frequency of the unit is correct when ordered and only use 60Hz units on 60Hz systems 50...

Page 16: ...bs GND Chassis Ground 5 16 stud 100 in lbs Table 3 3 Power Terminal Specifications 120 Amp Chassis TERMINALS FUNCTION ELECTRICAL RATINGS WIRE SIZE TORQUE L1 L2 L3 Power Input 120A 230 460VAC 3 8 stud 182 in lbs DC Bus Input 120A 750VDC 3 8 stud 182 in lbs GND Chassis Ground 5 16 stud 100 in lbs 3 4 2 I O WIRING M3345 Line Regens come with a status contact See Table 3 6 for Master Slave I O termina...

Page 17: ...ovided with Master Slave I O terminals for parallel operation See Figure 3 11 and Section 4 2 5 for more information Reference Table 3 6 when the unit is configured for Master Table 3 6 I O Terminal Specifications Y C W Z and V Chassis TERMINAL FUNCTION ELECTRICAL RATINGS WIRE SIZE TORQUE TS1 1 Master Slave 5A 250V 18 12 AWG 20 in lbs TS1 2 TS1 3 Master Slave 5A 250V 18 12 AWG 20 in lbs TS1 4 TS1 ...

Page 18: ... thru 3 11 illustrate typical connections of the M3345 Regen units with generic VFDs There are many other configurations that may be applied providing a basic connection criterion is maintained such as The AC input should maintain a low impedance path back to the grid No reactors should be connected upstream of the regen unit without consulting Bonitron for instructions Dwg s 080109 080110 Rev 200...

Page 19: ...ut of a VFD This should never be connected to a switching source such as the braking resistor terminals on some drives The DC input should not be connected to an active SCR front end drive without instructions from Bonitron Figure 3 9 M3345 10 120 Amp Single Drive Regen Field Wiring Diagram Dwg 010132 Rev 20070521 ...

Page 20: ...REGEN C B A AC LINE DC BUS RUN RPM HZ RUN STOP 0 1 2 3 5 4 6 7 8 9 T2 T1 T3 MOTOR AND DRIVE GND TYPICAL RUN RPM HZ RUN STOP 0 1 2 3 5 4 6 7 8 9 T2 T1 T3 MOTOR AND DRIVE GND TYPICAL RUN RPM HZ RUN STOP 0 1 2 3 5 4 6 7 8 9 T2 T1 T3 MOTOR AND DRIVE GND TYPICAL POS REGEN REGEN NEG AC LINE L3 L2 L1 DRIVE 1 DC DRIVE 2 DC DRIVE 3 DC DRIVE 3 DC DRIVE 2 DC DRIVE 1 DC TYPICAL M3345D DC DC 3 DRIVE DC BUS 2 D...

Page 21: ...ster Slave I O Connection Diagram STATUS M S I O STATUS M S I O STATUS M S I O STATUS M S I O M S I O STATUS 6 5 3 4 1 2 4th SLAVE 2nd SLAVE 6 5 3 4 1 2 6 4 5 3 2 1 3rd SLAVE 1st SLAVE 3 1 2 4 5 6 MASTER 6 5 4 2 1 3 Dwg 070129 Rev 20070522 ...

Page 22: ...ntrol Board Jumper Configuration For Single unit or Master operation J1 J2 must be in the M position For Slave operation J1 J2 must be in the S position R118 RUN STDBY LD1 LD2 I LIMIT R82 R159 OVER R89 S M J1 LOAD LD3 J2 S M ...

Page 23: ...he M3345 will also go into the shutdown mode upon loss of any phase of the incoming power The M3345 series of Regen Modules come standard with an internal bus structure which allows for regeneration from the drive to the AC Line only Power may be transferred from the AC drive to the regen however the regen will not provide energy to the AC drive 4 2 FEATURES Fusing Internal line filtering Current ...

Page 24: ...OR PARALLELING REGENS The M3345 regeneration units come equipped with Master Slave selectable control boards 60 Amp and 90 Amp units are available for Master Slave operations The S B and X chassis units 60 Amp do not provide I O connections for Master Slave operation It is imperative that when paralleling units one unit be configured as a Master and all others configured as Slaves This will allow ...

Page 25: ...on the ammeter If the cover is open the RUN LED should be illuminated on the 3345C2 control board see Figure 3 12 for location Status contact should be closed after a 2 second delay which is an indication that unit is ready for operation If any of the following conditions exist refer to Troubleshooting in Section 5 3 Front panel lamp off with power applied Status contact still open after 5 seconds...

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Page 27: ...ve any covers with power applied to the unit Refer to Figure 3 12 for location of the LEDs on the circuit board Following is a brief description of the LEDs and indications 5 3 1 POWER LAMP IS OUT Check AC input voltage at fuses Check voltage at output side of fuses Check connection to lamp from PCB 5 3 2 RUN LIGHT IS OUT The RUN LED indicates that the module is enabled and in a ready condition Th...

Page 28: ...y at fuse Check DC bus fuses Ensure unit is not overheated Verify proper sizing of regen unit 5 3 6 OVERLOAD LIGHT IS FLICKERING The normal state for the OVERLOAD LED is OFF The OVERLOAD LED may flash for a brief moment on power up The OVERLOAD LED indicates that the system DC bus feedback is substantially greater than the DC bus reference signal Under normal operating conditions this occurs when ...

Page 29: ...ICAL HELP BEFORE YOU CALL If technical help is required please have the following information available when calling Model number of unit Serial number of unit Name of original equipment supplier if available Record the Line to Line voltage on all 3 phases Record the DC bus voltage immediately after the AC voltage Brief description of the application Drive and motor hp or kW KVA rating of power so...

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Page 31: ...2BM00 TYPE 13 30 6 6 8 1 3 287 M3345 22BMF0 TYPE 13 30 20 6 8 4 5 734 M3345 22CMFM TYPE 13 30 30 6 8 6 8 1107 M3345 22Y F0 Open 30 30 6 8 6 8 1107 M3345 24SMF0 TYPE 1 45 30 10 7 1107 M3345 24X 00 Open 45 5 10 1 287 M3345 24X F0 Open 45 20 10 4 734 M3345 24BM00 TYPE 13 45 5 10 1 287 M3345 24BMF0 TYPE 13 45 20 10 4 734 M3345 24CMFM TYPE 13 45 45 10 10 1592 M3345 24Y F0 Open 45 45 10 10 1592 M3345 2A...

Page 32: ...0 TYPE 13 30 20 22 15 734 M3345 32CMFM TYPE 13 30 30 22 22 1107 M3345 32Y F0 Open 30 30 22 22 1107 M3345 34SMF0 TYPE 1 45 30 33 23 1107 M3345 34X 00 Open 45 5 33 4 287 M3345 34X F0 Open 45 20 33 15 734 M3345 34BM00 TYPE 13 45 5 33 4 287 M3345 34BMF0 TYPE 13 45 20 33 15 734 M3345 34CMFM TYPE 13 45 45 33 33 1592 M3345 34Y F0 Open 45 45 33 33 1592 M3345 3AWMFM TYPE 1 60 55 45 41 1965 M3345 3AY FM Ope...

Page 33: ...MF0 TYPE 13 30 20 27 18 734 M3345 42CMFM TYPE 13 30 30 27 27 1107 M3345 42Y F0 Open 30 30 27 27 1107 M3345 44SMF0 TYPE 1 45 30 41 27 1107 M3345 44X 00 Open 45 5 41 5 287 M3345 44X F0 Open 45 20 41 18 734 M3345 44BM00 TYPE 13 45 5 41 5 287 M3345 44BMF0 TYPE 13 45 20 41 18 734 M3345 44CMFM TYPE 13 45 45 41 41 1592 M3345 44Y F0 Open 45 45 41 41 1592 M3345 4AWMFM TYPE 1 60 55 54 50 1965 M3345 4AY FM O...

Page 34: ...ility of each unit Applications that do not utilize the full capacity may be calculated as follows hp 746 5 100 Watt Loss Where hp is the average estimated regen horsepower 6 3 CERTIFICATIONS There are presently no certifications for the M3345 Regen Unit If certification is required check with your integrator and or panel shop for full system certification The M3345 is constructed with industry gu...

Page 35: ...User s Manual 29 6 5 DIMENSIONS AND MECHANICAL DRAWINGS Figure 6 1 M3345 S Chassis Dimensional Outline 4 000 APPROX Dwg 010074 Rev 20070521 ...

Page 36: ...M3345 30 Figure 6 2 M3345 W Chassis Dimensional Outline Dwg 060230 Rev 20070521 ...

Page 37: ...User s Manual 31 Figure 6 3 M3345 V Chassis Dimensional Outline Dwg 070107 Rev 20070521 ...

Page 38: ...M3345 32 Figure 6 4 M3345 B Chassis Dimensional Outline Dwg 920306 Rev 20080310 ...

Page 39: ...User s Manual 33 Figure 6 5 M3345 B Chassis with Fan Dimensional Outline Dwg 940040 Rev 20080310 ...

Page 40: ...M3345 34 Figure 6 6 M3345 C Chassis Dimensional Outline Dwg 950191 Rev 20091229 ...

Page 41: ...User s Manual 35 Figure 6 7 M3345 X Chassis Dimensional Outline Dwg 920322 Rev 20080311 ...

Page 42: ...M3345 36 Figure 6 8 M3345 X Chassis with Fan Dimensional Outline Dwg 940190 Rev 20080311 ...

Page 43: ...User s Manual 37 Figure 6 9 M3345 Y Chassis Dimensional Outline Dwg 950052 Rev 20070928a ...

Page 44: ...M3345 38 Figure 6 10 M3345 Z Chassis Dimensional Outline Dwg 950246 Rev 20000927 mod ...

Page 45: ...F 3 1 OF 3 TIMING LOGIC IN CURRENT LIMIT WHEN UNIT IS ON BOARD CONTROL ON WHEN RUNNING LED RUN LOCK OUT LOW P S DELAY START UP FREQ GEN CARRIER BASE DRIVE DRIVE BASE ISOLATED LIMIT I GATE DRIVE ISOLATED 2 2 1 1 B E E B LED LIMIT SENSING CURRENT SENSING PHASE ISOLATED OPTICALLY 10V COM REG 12V B UN REG 2 E 1 E 2 B 1 B A A A POWER CONTROL MODULE di dt LIMITER C B A CTC CTB LL V 50HZ OR 60HZ Dwg 0002...

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Page 47: ...eed P 5250 TN where P Power Hp T Torque lb ft calculated above N Maximum shaft speed rpm Determine the DC bus current rating required for the regeneration module IDC P 1 2 for 460vac drives or IDC P 2 4 for 230vac drives where P Power Hp calculated above IDC Regen Amps 7 1 2 CALCULATING ENERGY SAVINGS The regeneration kit directs energy from the mechanical load to the power distribution line where...

Page 48: ...ristics Calculate the energy savings over a DB kit P 20 Hp peak 15 Hp average during deceleration D 365 days H 10 hours per day t T 5 on 15 total kW 0 08 per kW using S 15 0 746 5 15 365 10 0 08 Savings per year is S 1 089 16 Using the regen module the centrifuge customer is also able to reduce the braking time from 5 minutes to 1 5 minutes This results in a 30 increase in throughput for the machi...

Page 49: ...User s Manual 43 NOTES ...

Page 50: ...M3345 44 NOTES ...

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Page 52: ...D_M3345_CMAN_vall_05b 09 13 2011 521 Fairground Court Nashville Tennessee 37211 615 244 2825 FAX 615 244 2823 www bonitron com info bonitron com ...

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